Method and apparatus for forming a can shell using a draw-stretch process

ABSTRACT

A shell includes a body with a center panel, a countersink, a chuck wall, and a draw-stretched outer portion. The countersink has a base thickness. The outer portion has a reduced thickness. The shell countersink has substantially the same thickness as the sheet material prior to forming. In this configuration, the shell maintains the buckle resistance of a standard shell but uses less material.

BACKGROUND OF THE INVENTION Field of the Invention

The disclosed and claimed concept relates to metal shells and/or canends, and, more particularly, to shells and/or can ends made from areduced volume of metal. The disclosed concept also relates to a toolingassembly and associated methods for providing such shells and/or canends.

Background Information

Metallic containers (e.g., cans) are structured to hold products suchas, but not limited to, food and beverages. Generally, a metalliccontainer includes a can body and a can end. The can body, in anexemplary embodiment, includes a base and a depending sidewall. The canbody defines a generally enclosed space that is open at one end. The canbody is filled with product and the can end is then coupled to the canbody at the open end. The container is, in some instances, heated tocook and/or sterilize the contents thereof. This process increases theinternal pressure of the container. Further, the container contains, insome instances, a pressurized product such as, but not limited to acarbonated beverage. Thus, for various reasons, the container must havea minimum strength.

The can ends are either a “sanitary” can end or an “easy open” end. Asused herein, a “sanitary” end is a can end that does not have a tab orscore profile to open and would have to be opened by use of a can openeror other device. As used herein, an “easy open” can end includes a tearpanel and a tab. The tear panel is defined by a score profile, orscoreline, on the exterior surface (identified herein as the “publicside”) of the can end. The tab is attached (e.g., without limitation,riveted) adjacent the tear panel. The pull tab is structured to belifted and/or pulled to sever the scoreline and deflect and/or removethe severable panel, thereby creating an opening for dispensing thecontents of the container. The following addresses an “easy open” canend but is also applicable to a “sanitary” can end. That is, a“sanitary” can end is produced in a similar manner, and coupled to a canbody in a similar manner. Thus, as used herein, a can end is furtherdefined as including constructs that are used for both “sanitary” canends and “easy open” ends.

Generally, the strength of the container is related to the thicknessand/or volume of the metal from which the can body and the can end isformed, as well as, the shape of these elements. This applicationprimarily addresses the can ends rather than the can bodies. When thecan end is made, it originates as a blank, which is cut from a sheetmetal product (e.g., without limitation, sheet aluminum, sheet steel).As used herein, a “blank” is a portion of material that is formed into aproduct; the term “blank” is applicable to the portion of material untilall forming operations are complete. Further, as used herein, “aluminum”and “steel” include aluminum alloys and steel alloys, respectively.

In an exemplary embodiment, the blank is formed into a “shell” in ashell press. As used herein, a “shell,” or a “preliminary can end,” is aconstruct that started as a generally planar blank and which has beensubjected to forming operations other than scoring, paneling, rivetforming, and tab staking, as is known. FIG. 1 shows the selectedportions of a prior art shell 2 including a chuck wall 3, a can fitradius 4, a seaming panel 5, and a curl 6. Once all forming operationsare complete, the blank/shell is formed into a can end that isstructured to be coupled to a can body, as is known. Thus, it isunderstood that forming operations on the shell are related to thecharacteristics of the subsequently formed can end and container.Further, as the shell becomes the can end, hereinafter any discussion ordescription of a “shell” is also applicable to a “can end.”

In one embodiment, the press cuts a blank from a sheet of material andis formed into a shell at a single station. In another embodiment, theblank is cut from a sheet of material, or provided as a blank and isthen moved intermittently, or as used herein “indexed,” through thenumber of stations. That is, the blank is moved and stops at eachstation wherein a forming operation is performed (it is understood that,in some embodiments, some stations are “null” stations that do notperform a forming operation). Alternately, the press is a conversionpress that is structured to cut a blank from sheet material and form acan end as opposed to a shell. That is, a “can end” includes additionalconstructs such as, but not limited to, a tab coupled to the shell by arivet.

In the can making industry, large volumes of metal are required in orderto manufacture a considerable number of cans. This is a problem. Thus,an ongoing objective in the industry is to reduce the amount of metalused for each can. A reduction in the amount of metal is accomplished byreducing the thickness or gauge of the stock material which is alsoreferred to as “down-gauging,” or, the volume of metal used to createthe can end or can body is reduced. However, among other disadvantagesassociated with the formation of can ends from relatively thin gaugematerial or a reduced volume of metal, is the tendency of the can end towrinkle and/or buckle. That is, due to pressure produced from theproduct contained in the can to which the can end is attached, the canend will buckle if the can end is not structured to resist bucklingand/or is made from a material that is too thin. Such a pressure isproduced from a carbonated beverage or pressure that is the result fromsterilization or pasteurization processes involved in food and/orbeer/beverage applications. Standard can ends have a standard can end“buckle resistance” which, as used herein, means that can end isstructured to resist buckling when exposed to the pressures associatedwith a standard container of a standard size and made from a standardmaterial.

Containers of a standard size and made from a standard material are wellknown in the art. For example, a standard “pop” or “soda” container is atwelve ounce aluminum container as is well known in the art. Further,the pressure that such can end and container must resist are well known.Presently, can ends for such containers are made from blanks and/orshells that have, as used herein, a “standard volume.” That is, a“standard volume” means the volume of material associated with a shellor can end for a container of a standard size. The twelve ounce aluminumcontainer is one well known example. It is, however, understood thatthere are many standard size containers made from different materials.For example, a standard soup container includes an 18.6 ounce steel (orsteel alloy) container. Thus, a “standard volume” means the volume ofmaterial associated with a shell or can end for a container of anystandard size that is known in the art. As noted above, there is alwaysa need to reduce the amount of material used for shells, can ends, andcontainers. Accordingly, the use of a shell or can end that was formedfrom a blank with a standard volume is a problem. Thus, there is a needfor a shell and/or can end that utilizes a reduced amount of metal whilemaintaining buckle resistance.

Further, there is a need for a shell and/or can end that is structuredto operate with standard filling lines with standard ends without anymodifications to the filling line/seamer or seam chuck. That is, any newshell and/or can end must be compatible with existing standard seamers.A “seamer” is a machine that is structured to roll and compress thedistal end of the can body sidewall and the periphery of the can endtogether. As many can bodies and can ends are manufactured as a standardsize, such as, but not limited to, a twelve ounce beverage can, the canbodies and the can ends must be compatible with the seamers for suchstandard size can bodies and can ends. Accordingly, as used herein, a“standard seamer” is a machine that couples a can end to a can bodywherein the can bodies and can ends are manufactured as a standard size,such as, but not limited to, a twelve ounce beverage can. If the canbodies and can ends were not a standard size, the user would need toacquire machinery structured to accommodate the non-standard size canbodies and can ends. This is a problem.

There is, therefore, a need to decrease the amount of material in theshell and/or can end so as to decrease the total amount of material usedto create the can end. There is a further need for a shell and/or canend having a reduced amount of material to be compatible with existingmachinery for processing shells, can ends and can bodies.

SUMMARY OF THE INVENTION

These needs, and others, are met by at least one embodiment of thedisclosed and claimed concept which provides a shell made from a sheetmaterial blank with a reduced volume. As used herein, a “reduced volume”means that the volume is reduced relative to the volume of a prior artshell that is structured to be coupled to a can body of the same sizeand wherein the shell is made of the same material; that is, the sametype of metal which is the same thickness. As used herein, the shell hasa body with an “inner portion” that includes a center panel and acountersink. Contiguous with the shell body inner portion is, as usedherein, the shell body “outer portion” that includes a chuck wall, acrown radius, a can fit radius, and a curl. The disclosed and claimedconcept provides for a shell body “outer portion” with a reducedthickness.

That is, in an exemplary embodiment, the shell includes a body with adraw-stretched chuck wall, crown radius, can fit radius, and/or curl.The center panel and the countersink have a base thickness. Any of thechuck wall, the crown radius, the can fit radius, and/or the curl have areduced thickness. The shell countersink and the shell chuck wall havesubstantially the same thickness as the sheet material prior to forming.In this configuration, the shell maintains the buckle resistance of astandard shell but uses less material. The use of such a shell solvesthe problems stated above. Further, the shell is compatible withexisting machinery for processing shells, can ends and can bodies. Apress and a method for forming such shells is also disclosed and solvethe problems stated above.

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of the invention can be gained from the followingdescription of the preferred embodiments when read in conjunction withthe accompanying drawings in which:

FIG. 1 is a schematic cross-sectional side view of a prior art shell.

FIG. 2 is a partial cross-sectional side view of an uncurled shell.

FIG. 3 is a partially schematic side view and partially cross-sectionalside view of a press.

FIG. 4 is a partially schematic side view and partially cross-sectionalside view of a first forming station.

FIGS. 5A-15A are detail cross-sectional side views of one embodiment ofa first forming station at sequential configurations during the formingof a shell. FIGS. 5B-15B are detail cross-sectional side views ofanother embodiment of a first forming station at sequentialconfigurations during the forming of a shell. FIG. 15C is a schematiccross-sectional view comparing the profiles of the tooling in FIGS. 5Aand 5B.

FIG. 16 is a flow chart of the disclosed method.

FIG. 17A is a schematic cross-sectional side view of a shell having areduced profile. FIG. 17B is a schematic cross-sectional side view of ashell having a maximum reduced profile.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

It will be appreciated that the specific elements illustrated in thefigures herein and described in the following specification are simplyexemplary embodiments of the disclosed concept, which are provided asnon-limiting examples solely for the purpose of illustration. Therefore,specific dimensions, orientations, assembly, number of components used,embodiment configurations and other physical characteristics related tothe embodiments disclosed herein are not to be considered limiting onthe scope of the disclosed concept.

Directional phrases used herein, such as, for example, clockwise,counterclockwise, left, right, top, bottom, upwards, downwards andderivatives thereof, relate to the orientation of the elements shown inthe drawings and are not limiting upon the claims unless expresslyrecited therein.

As used herein, the singular form of “a,” “an,” and “the” include pluralreferences unless the context clearly dictates otherwise.

As used herein, “structured to [verb]” means that the identified elementor assembly has a structure that is shaped, sized, disposed, coupledand/or configured to perform the identified verb. For example, a memberthat is “structured to move” is movably coupled to another element andincludes elements that cause the member to move or the member isotherwise configured to move in response to other elements orassemblies. As such, as used herein, “structured to [verb]” recitesstructure and not function. Further, as used herein, “structured to[verb]” means that the identified element or assembly is intended to,and is designed to, perform the identified verb. Thus, an element thatis merely capable of performing the identified verb but which is notintended to, and is not designed to, perform the identified verb is not“structured to [verb].”

As used herein, “associated” means that the elements are part of thesame assembly and/or operate together, or, act upon/with each other insome manner. For example, an automobile has four tires and four hubcaps. While all the elements are coupled as part of the automobile, itis understood that each hubcap is “associated” with a specific tire.

As used herein, a “coupling assembly” includes two or more couplings orcoupling components. The components of a coupling or coupling assemblyare generally not part of the same element or other component. As such,the components of a “coupling assembly” may not be described at the sametime in the following description.

As used herein, a “coupling” or “coupling component(s)” is one or morecomponent(s) of a coupling assembly. That is, a coupling assemblyincludes at least two components that are structured to be coupledtogether. It is understood that the components of a coupling assemblyare compatible with each other. For example, in a coupling assembly, ifone coupling component is a snap socket, the other coupling component isa snap plug, or, if one coupling component is a bolt, then the othercoupling component is a nut.

As used herein, a “fastener” is a separate component structured tocouple two or more elements. Thus, for example, a bolt is a “fastener”but a tongue-and-groove coupling is not a “fastener.” That is, thetongue-and-groove elements are part of the elements being coupled andare not a separate component.

As used herein, the statement that two or more parts or components are“coupled” shall mean that the parts are joined or operate togethereither directly or indirectly, i.e., through one or more intermediateparts or components, so long as a link occurs. As used herein, “directlycoupled” means that two elements are directly in contact with eachother. As used herein, “fixedly coupled” or “fixed” means that twocomponents are coupled so as to move as one while maintaining a constantorientation relative to each other. Accordingly, when two elements arecoupled, all portions of those elements are coupled. A description,however, of a specific portion of a first element being coupled to asecond element, e.g., an axle first end being coupled to a first wheel,means that the specific portion of the first element is disposed closerto the second element than the other portions thereof. Further, anobject resting on another object held in place only by gravity is not“coupled” to the lower object unless the upper object is otherwisemaintained substantially in place. That is, for example, a book on atable is not coupled thereto, but a book glued to a table is coupledthereto.

As used herein, the phrase “removably coupled” or “temporarily coupled”means that one component is coupled with another component in anessentially temporary manner. That is, the two components are coupled insuch a way that the joining or separation of the components is easy andwould not damage the components. For example, two components secured toeach other with a limited number of readily accessible fasteners, i.e.,fasteners that are not difficult to access, are “removably coupled”whereas two components that are welded together or joined by difficultto access fasteners are not “removably coupled.” A “difficult to accessfastener” is one that requires the removal of one or more othercomponents prior to accessing the fastener wherein the “other component”is not an access device such as, but not limited to, a door.

As used herein, “temporarily disposed” means that a first element(s) orassembly (ies) is resting on a second element(s) or assembly(ies) in amanner that allows the first element/assembly to be moved without havingto decouple or otherwise manipulate the first element. For example, abook simply resting on a table, i.e., the book is not glued or fastenedto the table, is “temporarily disposed” on the table.

As used herein, “operatively coupled” means that a number of elements orassemblies, each of which is movable between a first position and asecond position, or a first configuration and a second configuration,are coupled so that as the first element moves from oneposition/configuration to the other, the second element moves betweenpositions/configurations as well. It is noted that a first element maybe “operatively coupled” to another without the opposite being true.

As used herein, “correspond” indicates that two structural componentsare sized and shaped to be similar to each other and may be coupled witha minimum amount of friction. Thus, an opening which “corresponds” to amember is sized slightly larger than the member so that the member maypass through the opening with a minimum amount of friction. Thisdefinition is modified if the two components are to fit “snugly”together. In that situation, the difference between the size of thecomponents is even smaller whereby the amount of friction increases. Ifthe element defining the opening and/or the component inserted into theopening are made from a deformable or compressible material, the openingmay even be slightly smaller than the component being inserted into theopening. With regard to surfaces, shapes, and lines, two, or more,“corresponding” surfaces, shapes, or lines have generally the same size,shape, and contours.

As used herein, a “path of travel” or “path,” when used in associationwith an element that moves, includes the space an element moves throughwhen in motion. As such, any element that moves inherently has a “pathof travel” or “path.” Further, a “path of travel” or “path” relates to amotion of one identifiable construct as a whole relative to anotherobject. For example, assuming a perfectly smooth road, a rotating wheel(an identifiable construct) on an automobile generally does not moverelative to the body (another object) of the automobile. That is, thewheel, as a whole, does not change its position relative to, forexample, the adjacent fender. Thus, a rotating wheel does not have a“path of travel” or “path” relative to the body of the automobile.Conversely, the air inlet valve on that wheel (an identifiableconstruct) does have a “path of travel” or “path” relative to the bodyof the automobile. That is, while the wheel rotates and is in motion,the air inlet valve, as a whole, moves relative to the body of theautomobile.

As used herein, the statement that two or more parts or components“engage” one another means that the elements exert a force or biasagainst one another either directly or through one or more intermediateelements or components. Further, as used herein with regard to movingparts, a moving part may “engage” another element during the motion fromone position to another and/or may “engage” another element once in thedescribed position. Thus, it is understood that the statements, “whenelement A moves to element A first position, element A engages elementB,” and “when element A is in element A first position, element Aengages element B” are equivalent statements and mean that element Aeither engages element B while moving to element A first position and/orelement A either engages element B while in element A first position.

As used herein, “operatively engage” means “engage and move.” That is,“operatively engage” when used in relation to a first component that isstructured to move a movable or rotatable second component means thatthe first component applies a force sufficient to cause the secondcomponent to move. For example, a screwdriver may be placed into contactwith a screw. When no force is applied to the screwdriver, thescrewdriver is merely “temporarily coupled” to the screw. If an axialforce is applied to the screwdriver, the screwdriver is pressed againstthe screw and “engages” the screw. However, when a rotational force isapplied to the screwdriver, the screwdriver “operatively engages” thescrew and causes the screw to rotate. Further, with electroniccomponents, “operatively engage” means that one component controlsanother component by a control signal or current.

As used herein, the word “unitary” means a component that is created asa single piece or unit. That is, a component that includes pieces thatare created separately and then coupled together as a unit is not a“unitary” component or body.

As used herein, the term “number” shall mean one or an integer greaterthan one (i.e., a plurality). That is, for example, the phrase “a numberof elements” means one element or a plurality of elements.

As used herein, in the phrase “[x] moves between its first position andsecond position,” or, “[y] is structured to move [x] between its firstposition and second position,” “[x]” is the name of an element orassembly. Further, when [x] is an element or assembly that moves betweena number of positions, the pronoun “its” means “[x],” i.e., the namedelement or assembly that precedes the pronoun “its.”

As used herein, “about” in a phrase such as “disposed about [an element,point or axis]” or “extend about [an element, point or axis]” or “[X]degrees about an [an element, point or axis],” means encircle, extendaround, or measured around. When used in reference to a measurement orin a similar manner, “about” means “approximately,” i.e., in anapproximate range relevant to the measurement as would be understood byone of ordinary skill in the art.

As used herein, a “radial side/surface” for a circular or cylindricalbody is a side/surface that extends about, or encircles, the centerthereof or a height line passing through the center thereof. As usedherein, an “axial side/surface” for a circular or cylindrical body is aside that extends in a plane extending generally perpendicular to aheight line passing through the center. That is, generally, for acylindrical soup can, the “radial side/surface” is the generallycircular sidewall and the “axial side(s)/surface(s)” are the top andbottom of the soup can.

As used herein, a “product side” means the side of a construct used in acontainer that contacts, or could contact, a product such as, but notlimited to, a food or beverage. That is, the “product side” of theconstruct is the side of the construct that, eventually, defines theinterior of a container.

As used herein, a “customer side” means the side of a construct used ina container that does not contact, or could not contact, a product suchas, but not limited to, a food or beverage. That is, the “customer side”of the construct is the side of the construct that, eventually, definesthe exterior of a container.

As used herein, “generally curvilinear” includes elements havingmultiple curved portions, combinations of curved portions and planarportions, and a plurality of planar portions or segments disposed atangles relative to each other thereby forming a curve.

As used herein, “generally” means “in a general manner” relevant to theterm being modified as would be understood by one of ordinary skill inthe art.

As used herein, “substantially” means “for the most part” relevant tothe term being modified as would be understood by one of ordinary skillin the art.

As used herein, “at” means on and/or near relevant to the term beingmodified as would be understood by one of ordinary skill in the art.

As used herein, “standard,” as used in “standard container” or “standardshell,” means a construct used in association with a specific productand which is used by more than one product manufacturer. As noted above,for a product such as soda, pop, and/or beer, many manufacturers use analuminum twelve fluid ounce container. Thus, such a container, as wellas the components therefore (e.g., the shell, can end, and can body), isa “standard” container, a “standard” shell, a “standard” can end, and a“standard” can body. “Standard” containers, as well as the componentstherefore, are well known in the art.

As used herein, to “draw-stretch” means that a portion of a metal blankis clamped between forming constructs and pulled therebetween. Thisaction both draws the metal and stretches the metal. As used herein, to“draw” metal means that the metal is thinned by pulling the metalbetween two dies that are spaced by a distance thinner than the metal.As used herein, to “stretch” metal means that the metal is held at aplurality of locations and pulled. This action results in the metalthinning between the held points. Thus, to “draw-stretch” a blankcombines these two actions. Further, as used herein, “draw-stretching”is not the same as any of “drawing,” “stretching,” or ironing the metal.Further, as used herein, “clamp(ed)” means that a blank is disposedbetween two forming constructs and a bias is applied to the blanksufficient to prevent the formation of wrinkles but not sufficient toprevent the metal from moving between the forming constructs.

The following description provides for forming a shell 20, shown in FIG.2, including an inner portion 24 and an outer portion 26 that aredivided by boarder “B.” The shell 20 is made from a reduced volume ofmaterial and having a draw-stretched outer portion 26. That is, as usedherein, the outer portion 26 includes a chuck wall 34, a can fit radius35, a crown radius 36, and a curl 38. As used herein, “a chuck wall 34,a draw-stretched can fit radius 35, draw-stretched crown radius 36,draw-stretched curl 38 are thinned via draw-stretch forming, or thatcollectively all elements, i.e., the outer portion 26 is thinned viadraw-stretch forming.

As is known, the shell 20 is initially a blank 10 (FIG. 3) cut fromsheet material 1. The sheet material 1, and therefore the blank 10, havea base thickness. Unless altered by forming operations, as describedbelow, portions of the blank 10 and the shell 20, and therefore theresulting can end (not shown), maintain the base thickness. That is, asshown in FIG. 3, the blank 10 includes a center panel portion 11, acountersink portion 12, a chuck wall portion 14, a can fit radiusportion 15, a crown radius portion 16, and a curl portion 18 which,following forming operations, become a center panel 30, a countersink32, a draw-stretched chuck wall 34, a draw-stretched can fit radius 35,a draw-stretched crown radius 36, and a curl 38, respectively, asdiscussed below. The draw-stretched chuck wall 34, draw-stretched canfit radius 35, draw-stretched crown radius 36 are, as used herein,collectively identified as the “draw-stretched outer portion 26”

Further, the following discussion and the Figures use a generallycylindrical shell 20 as an example. It is understood that the disclosedand claimed concept is operable with shells 20 of any shape and thecylindrical shape discussed and shown is exemplary only. Further, in anexemplary embodiment and for the dimensions described below, the shellis made from aluminum and is structured to be coupled to a beverage can;that is, a can structured to contain a beverage such as beer orcarbonated beverages, i.e., a “soda” or “pop.” As used herein, suchshell is identified as a “beverage container shell” 20′. Onenon-limiting example of a beverage can having a beverage container shell20′ is a twelve ounce beverage container. The “standard volume,” asdefined above, for a blank 10 and the subsequent beverage containershell 20′ is substantially about 0.0546 in³. As is known, such astandard blank (not shown) was formed into a shell with the followingcharacteristics. One embodiment of a standard volume beverage containershell 20′ (FIG. 1) has the following characteristics.

Volume 0.0546 in³ Base Thickness 0.0086 in. Structured to Resist aPressure of 90 psi

It is understood that shells 20 for other standard containers (noneshown) have different characteristics that are well known in the art.

The blank 10 is formed into a shell 20 including a body 22 with a centerpanel 30, a countersink 32, a draw-stretched chuck wall 34, adraw-stretched can fit radius 35, a draw-stretched crown radius 36,and/or a draw-stretched curl 38. As used herein, “draw-stretched” meansthat the identified element has been draw-stretched so as to be thinnerthan in the prior art. As the draw-stretched element(s) is/are thinner,the blank 10 requires less metal, i.e., has a reduced volume, relativeto the prior art. This solves the problems stated above. Further, a“draw-stretched” element has a thickness that is thinner than the basethickness of the sheet material and/or the blank 10. Thus, as usedherein, a term such as “draw-stretched crown radius” 36 recites thecharacteristics such as, but not limited to, thickness of the crownradius and does not recite a product-by-process.

The inner portion 24, center panel 30 and the countersink 32 have a basethickness that generally corresponds to the sheet material 1 basethickness. The draw-stretched outer portion 26, i.e., the draw-stretchedchuck wall 34, the draw-stretched can fit radius 35, the draw-stretchedcrown radius 36, and/or the draw-stretched curl 38 has/have a reducedthickness or a specific reduced thickness. That is, as used herein, a“reduced thickness” means that the draw-stretched chuck wall 34, thedraw-stretched can fit radius 35, the draw-stretched crown radius 36,and/or the draw-stretched curl 38 have a thickness that is between about5% to about 21% thinner than the base gauge. As used herein, a “specificreduced thickness” means that the draw-stretched chuck wall 34,draw-stretched can fit radius 35, the draw-stretched crown radius 36,and/or the draw-stretched curl 38 have a thickness that is about 11%thinner than the base gauge. As used herein, a shell 20 that includesthe draw-stretched chuck wall 34, the draw-stretched can fit radius 35,the draw-stretched crown radius 36, and/or the draw-stretched curl 38 ismade from a “reduced volume of material” but maintains the buckleresistant characteristics of a standard shell. That is, a “beverage”container shell 20′ made from a “reduced volume of material” and whichincludes a draw-stretched outer portion 26 has the followingcharacteristics:

Volume 0.0533 in³ Base Thickness 0.0086 in. Structured to Resist aPressure of 90 psi

Further, a beverage container shell 20′ according to this disclosure isshown in FIG. 17A which shows the percentage decrease in the thicknessof the metal (relative to base thickness) at the draw-stretched chuckwall 34, the can fit radius 35, the draw-stretched crown radius 36, andthe curl 38, e.g., the outer portion 26. In this embodiment, the volumeof metal in the draw-stretched crown radius 36 is reduced (relative to astandard volume container shell) between about 5% to about 20%, or about11%. Stated alternately, in a reduced volume shell 20 (or reduced volumeshell body 22), the draw-stretched chuck wall 34, the can fit radius 35,the draw-stretched crown radius 36, and the curl 38, have a “reducedprofile.” That is, as used herein, a “reduced profile” means that thethickness of the metal relative to base thickness at the draw-stretchedchuck wall 34, the can fit radius 35, the draw-stretched crown radius36, and the curl 38 is reduced as described in the next sentence. Thethickness of the metal relative to base thickness at the draw-stretchedchuck wall 34 is reduced about 8.9% and 13.2%, the can fit radius 35 isreduced between about 13.2% to about 8.9%, the thickness of the metalrelative to base thickness at the draw-stretched crown radius 36 isreduced between about 8.9% and about 13.2%, and the thickness of themetal relative the base thickness at the curl 38 is reduced betweenabout 4.9% and about 10.3%.

Further, a shell 20 made from a “reduced volume of material” and whichincludes the draw-stretched chuck wall 34, the draw-stretched can fitradius 35, the draw-stretched crown radius 36, the draw-stretched curl38, and/or a draw-stretched solves the problems stated above. As usedherein, a “reduced volume of material” for the shell 20′ is measuredrelative to a standard shell and means that volume of the blank 10/shell20 is between about 2% to about 4% less, or about 2.4% less, than thevolume of a blank for a similar blank/shell (i.e., a blank/shellstructured to be coupled to the same size can body) that does not have adraw-stretched chuck wall 34, a draw-stretched can fit radius 35, adraw-stretched crown radius 36, and/or a draw-stretched curl 38.Further, such a blank 10, or such a shell 20, is, as used herein, a“reduced volume blank” 10 or a “reduced volume shell” 20.

In another exemplary embodiment, as shown in FIG. 17B, the beveragecontainer shell 20′ (or reduced volume shell body 22) has a “maximumreduced profile.” As used herein, a “maximum reduced profile” means thatthe thickness of the metal relative to the base thickness at thedraw-stretched chuck wall 34, the draw-stretched can fit radius 35, thedraw-stretched crown radius 36, and/or the draw-stretched curl 38 isreduced as shown in FIG. 17B. As shown, the thickness of the metalrelative to base thickness at the draw-stretched chuck wall 34 isreduced between about 25% to about 27%, can fit radius 35 is reducedbetween about 25% to about 27%, the thickness of the metal relative tobase thickness at the draw-stretched crown radius 36 is reduced about27%, and the thickness of the metal relative to the base thickness atthe curl 38 is reduced about 25%. Thus, a reduced volume shell 20 (orreduced volume shell body 22) has one of a “reduced profile” or a“maximum reduced profile.”

For example, for a beverage container shell 20′ the shell body 22 isaluminum, the countersink 32 has a general thickness of between about0.0082 inch and about 0.0106 inch or about 0.0086 inch. Thedraw-stretched chuck wall 34 has a general thickness of between aboutbetween about 0.0056 inch and about 0.0090 inch or about 0.0086 inch.The draw-stretched can fit radius 35 has a thickness of between about0.0056 inch or about 0.0090 inch, or about 0.0078 inch. Thedraw-stretched crown radius 36 has a general thickness of between about0.0056 inch and about 0.0090 inch or about 0.0078 inch. Thedraw-stretched curl 38 has a thickness of between about 0.0060 inch orabout 0.0094 inch, or about 0.0082 inch. As used herein, the “generalthickness” means the thickness of the material measured along a linegenerally perpendicular to the surface of the identified portion of theshell 20 at a specific location. Thus, for example, the “generalthickness” of the countersink 32 does not mean the width of thecountersink 32. Such a beverage container shell 20′ has, generally, thesame dimensions as a standard beverage shell and, as such, the beveragecontainer shell 20′ is structured to be processed in a mannersubstantially similar to a standard beverage shell. That is, thebeverage container shell 20′ does not require the use of new processingequipment and, as such, solves the problems stated above. Further, thebeverage container shell 20′ is structured to be coupled to a beveragecan body (not shown) and is structured to have a standard can end“buckle resistance.”

As another example, a shell for a steel container (not shown), such as,but not limited to an 18.6 ounce soup container, includes a steel shellbody 22 formed from a steel sheet material with a base thickness ofabout 0.0079 inch. A shell 20 for such a container includes acountersink 32 that has a general thickness of between about 0.0088 inchand about 0.0075 inch, or about 0.0079 inch. Further, in thisembodiment, the draw-stretched elements further include thedraw-stretched chuck wall 34, the draw-stretched can fit radius 35, thedraw-stretched crown radius 36, and/or the draw-stretched curl 38. Forsuch a steel shell 20, the draw-stretched chuck wall 34 has a generalthickness of between about 0.0056 inch and about 0.0084 inch, or about0.0072 inch, the draw-stretched can fit radius 35 has a thickness ofbetween about 0.0056 inch or about 0.0084 inch, or about 0.0072 inch.The draw-stretched crown radius 36 has a general thickness of betweenabout 0.0056 inch and about 0.0084 inch or about 0.0072 inch. Thedraw-stretched curl 38 has a thickness of between about 0.0060 inch orabout 0.0088 inch, or about 0.0076 inch. It is again noted that thespecific reductions in thickness in this paragraph are exemplary andthat the specific thickness of a draw-stretched element varies with theoriginal base thickness of the material.

The shell 20 made from a “reduced volume of material” and which includesthe draw-stretched chuck wall 34, the draw-stretched can fit radius 35,the draw-stretched crown radius 36, and/or the draw-stretched curl 38 isformed in a press assembly (or “press”) 500, as shown in FIGS. 2-14. Inanother embodiment, a shell 20 made from a “reduced volume of material”and which includes the draw-stretched chuck wall 34, the draw-stretchedcan fit radius 35, and/or the draw-stretched crown radius 36 is formedin a press assembly (or “press”) 500. That is, compared to the priorembodiment, the draw-stretched curl 38 is not formed in the press 500,but is formed at another station 502 or another press (not shown). Thus,the press 500 is structured to, and does, form a reduced volume shell20.

As noted above, in one embodiment, the press 500 includes a singlestation that both cuts the blank 10 from a sheet material 1 and formsthe blank 10 into a shell 20. In another embodiment, the press 500includes a number of stations 502 (some shown schematically) each ofwhich perform a number of forming operations on the shell 20 (as shownin the Figures, stations are generically identified by reference number502). For example, in one embodiment, a station 502 cuts a generallycircular, disk-like blank 10, which is a reduced volume blank 10, fromthe sheet material 1. Alternatively, a pre-cut reduced volume blank 10is fed into the press 500. Thus, the press 500 is structured to, anddoes, form a shell 20 from a blank 10 wherein the blank 10 is cut from asheet material 1. Whether the press 500 cuts the blank 10 from the sheetmaterial 1 is not relevant to this disclosure. Further, in one exemplaryembodiment, the sheet material 1 has forming operations performedthereon prior to cutting the blank 10 from the sheet material 1, or,prior to forming operations by a “first” forming station 530, discussedbelow. Thus, as used herein, the blank 10 is also a shell 20.Accordingly, the following discussion addresses a press 500 acting oneither a blank 10 or a shell 20.

As noted above, the shell 20 is, in one embodiment, formed in aone-stage process. That is, as used herein, a “one-stage process” meansthat all forming operations occur at a single station. Statedalternately, for a “one-stage process” the number of stations 502includes only a single station, which is identified herein as the“first” forming station 530.

In another embodiment, the blank 10, and/or shell 20, moves through thepress 500 on a conveyor 504, shown schematically in FIG. 3 that isstructured to, and does, move with an intermittent, or indexed, motion.In an exemplary embodiment, the conveyor 504 is a belt 506 (shownschematically) including a number of recesses, not shown. The belt 506moves a set distance then stops before moving the set distance again. Asthe belt 506 moves, the blank 10/shell 20 is moved sequentially throughthe conversion press number of stations 502 where, as noted above, eachstation 502 performs a single forming operation, or a number of formingoperations, on the blank 10/shell 20.

The press 500 also includes a frame 508 and a drive assembly (not shown)as well as a number of upper tooling assemblies 510 and a number oflower tooling assemblies 520. In an exemplary embodiment, each lowertooling assembly 520 is movably coupled, movably and directly coupled,or fixed to the press frame 508 and is generally stationary. Each uppertooling assembly 510 is structured to, and does, move between a firstposition, wherein the upper tooling assembly 510 is spaced from thelower tooling assembly 520, and a second position, wherein the uppertooling assembly 510 is closer to, and in an exemplary embodiment,immediately adjacent, the lower tooling assembly 520. As used herein,“immediately adjacent” means that the upper tooling assembly 510 isspaced from the lower tooling assembly 520 so that the toolingassemblies 510, 520 form, i.e., change the shape of, the blank 10/shell20. In an exemplary embodiment, each of the upper tooling assembly 510and a lower tooling assembly 520 for multiple stations 502 are unitaryor coupled and support the dies, punches and other elements of eachstation. In this configuration, the upper tooling assemblies 510 for thestations move at the same time and are driven by a single drive assembly(not shown). Further, and as is known, the upper tooling assembly 510and the lower tooling assembly 520 include separately movable elements,e.g., punches, dies, spacers, pads, risers and other sub-elements(collectively hereinafter, “sub-elements”) discussed below, that arestructured to, and do, move separately from each other. All elements,however, generally move with the upper tooling assembly 510 betweenfirst and second positions. That is, generally, the motions of thesub-elements are relative to each other but as a whole, the uppertooling assembly 510 moves between the first position and the secondposition as described above. Further, it is understood that the driveassembly includes cams, linkages, and other elements that are structuredto move the sub-elements of the upper tooling assembly 510 and the lowertooling assembly 520 in the proper order. That is, selected sub-elementsof the upper tooling assembly 510 and the lower tooling assembly 520 arestructured to move independently of other selected sub-elements. Forexample, one selected sub-element is structured to move into, and dwell,at the second position while another sub-element moves into and out ofthe second position. Such selective motion of the sub-elements is knownin the art. For the purpose of this disclosure, only a first formingstation 530, or a single forming station 530, is relevant andhereinafter the upper tooling assembly 510 and the lower toolingassembly 520 are identified as the first forming station upper toolingassembly 510 and the first forming station lower tooling assembly 520.The first forming station 530 is structured to, and does, form the shellbody 22 to have the center panel 30, the countersink 32, thedraw-stretched chuck wall 34, and the draw-stretched crown radius 36, asdiscussed above. Stated alternately, the first forming station uppertooling assembly 510 and the first forming station lower toolingassembly 520 are structured to, and do, form the shell body 22 to havethe center panel 30, the countersink 32, the draw-stretched chuck wall34, the draw-stretched can fit radius 35, and the draw-stretched crownradius 36. That is, the first forming station upper tooling assembly 510and the first forming station lower tooling assembly 520 are structuredto, and do, form the countersink portion 12 into a countersink 32, thechuck wall portion 14 into the draw-stretched chuck wall 34, the can fitradius portion 15 into the draw-stretched can fit radius 35, and thecrown radius portion 16 into the draw-stretched crown radius 36. Thus,the first forming station upper tooling assembly 510 and the firstforming station lower tooling assembly 520 are structured to, and do,draw-stretch the chuck wall portion 14/can fit radius portion 15/crownradius portion 16 to create an outer portion 26, or a crown radius 36,with a reduced thickness. Further, the press 500 is structured to formthe center panel 30 and the countersink 32, or inner portion 24, whilesubstantially maintaining the base thickness of the sheet material 1. Inthis configuration, the blank 10/shell 20 with a reduced volume and witha draw-stretched outer portion 26 solves the problems stated above.

In an exemplary embodiment, the first forming station upper toolingassembly 510 includes a “blank & draw” die punch 512, an upper piston514, and a die center punch 516. The forming station upper toolingassembly blank & draw die punch 512 (hereinafter “first forming stationupper blank & draw die punch” 512) includes a generally toroid body 531.The first forming station upper blank & draw die punch body 531 includesan axial surface 532 and an inner radial surface 534. The innerintersection of the first forming station upper blank & draw die punchtoroid body axial surface 532 and the first forming station upper blank& draw die punch toroid body inner radial surface 534 is curvilinear andthis transition area is, as used herein, the “inner radius” 536. Thatis, the term “inner radius” does not mean the radius that defines thefirst forming station upper blank & draw die punch toroid body innerradial surface 534. Moreover, in an exemplary embodiment, the firstforming station upper blank & draw die punch inner radial surface 536 isa “reduced radius” (hereinafter, also identified as the “first formingstation upper blank & draw die punch reduced inner radial surface” 536).As used herein, a “reduced radius” means that the radius is reducedbetween about 68% and about 88%, or about 80% relative to the radius ofa comparable first forming station upper blank & draw die punch innerradial surface structured to make a similar shell.

FIGS. 5A-15A show an embodiment of the press 500 wherein the firstforming station upper tooling assembly 510 includes a die center punch516A. FIGS. 5B-15B show an embodiment of the press 500 wherein the firstforming station upper tooling assembly 510 includes a die center punch516B. FIG. 15C shows a comparison between the die center punch 516A andthe die center punch 516B. The motions of the elements of the firstforming station 530 would be understood by one of ordinary skill in theart as shown in FIGS. 5A-15A and 5B-15B.

Further, in an exemplary embodiment, the first forming station lowertooling assembly 520 includes a lower piston 522 (alternatelyhereinafter, “first forming station lower piston” 522), a die core ring524, and a panel punch 526. The first forming station lower toolingassembly die core ring 524 (hereinafter, the “first forming stationlower die core ring” 524) includes a generally toroid body 540 with andaxial surface 542 and an outer radial surface 544. The intersection ofthe first forming station lower die core ring toroid body axial surface542 and the first forming station lower die core ring toroid body outerradial surface 544 is curvilinear and this transition area is, as usedherein, the “outer radius” 546; that is, the term “outer radius” doesnot mean the radius that defines the first forming station upper blank &draw die punch toroid body outer radial surface 544.

Moreover, in an exemplary embodiment, the first forming station lowerdie core ring outer radius 546 is a “diminished radius” (hereinafter,also identified as the “first forming station lower die core ringdiminished outer radius” 546). As used herein, a “diminished radius”means that the radius is reduced between about 30% and about 60%, orabout 50% relative to the radius of a comparable first forming stationlower die core ring radial surface structured to make a similar shell.

In an exemplary embodiment, wherein the press is structured to form abeverage container shell 20′, the first forming station upper blank &draw die punch inner radial surface 536 is about a 0.019 inch radius,and the first forming station lower die core ring outer radius 546 isabout a 0.022 inch radius.

Further, the draw-stretched outer portion 26 is formed by“draw-stretching” as defined above. Accordingly, the press 500 isstructured to, and does, “clamp” the crown radius portion 16 of theblank 10, as defined above. Thus, when the first forming station uppertooling assembly 510 is in the second position, the first formingstation upper blank & draw die punch 512 and the first forming stationlower piston 522 apply a force of between about 60 psi and about 250psi, or about 110 psi, to the blank 10/shell 20. Stated alternately, thepressure relative to the prior art pressure of 50 psi for thesecomponents, is increased between about 20% to about 400% or about 200%.Further, the upper piston 514 and the first forming station lower diecore ring 524 apply a force of between about 100 psi and about 600 psi,or about 110 psi. Stated alternately, the pressure relative to the priorart pressure of 50 psi for these components is increased between about100% to about 1100% or about 800%.

As used herein, the pressure ranges noted in the prior paragraph are a“draw-stretching” pressure range for the identified components. That is,a force of between about 60 psi and about 250 psi is the“draw-stretching” pressure range for the first forming station upperblank & draw die punch 512 and the first forming station lower piston522. The press 500 is structured to, and does, apply the“draw-stretching” pressure range to each pair of components. Further,the specific pressure noted in the prior paragraph is the“draw-stretching” pressure for the identified components. The press 500is structured to, and does, apply the “draw-stretching” pressure to eachpair of components.

As noted above, the terms blank 10 and the shell 20 are interchangeable;thus, as used herein when discussing the press 500, the terms “blank” 10or “shell” 20 are interchangeable and mean the construct that is beingformed.

It is understood that the combination of the first forming station upperblank & draw die punch reduced inner radial surface 536, the firstforming station lower die core ring diminished outer radius 546, and theincreased pressure of the first forming station upper blank & draw diepunch 512 and the first forming station lower piston 522 that arestructured to, and do, form the draw-stretched outer portion 26 andsolve the problems stated above.

As shown in FIG. 16, a method of forming the shell 20 with adraw-stretched outer portion 26 includes providing 1000 a sheet material1, the sheet material 1 having a base thickness, cutting 1002 a blank 10from the sheet material 1, the blank 10 including a countersink portion12, a chuck wall portion 14, and a crown radius portion 16, providing1004 a press assembly 500 including a frame 508, a number of pressstations 502 including a first forming station 530, the first formingstation 530 including an upper tooling assembly 510 and a lower toolingassembly 520, the first forming station upper tooling assembly 510structured to move between an upper, first position, wherein the firstforming station upper tooling assembly 510 is spaced from the firstforming station lower tooling assembly 520, and a lower, secondposition, wherein the first forming station upper tooling assembly 510is immediately adjacent the first forming station lower tooling assembly520, wherein when the first forming station upper tooling assembly 510and the first forming station lower tooling assembly 520 are in thesecond position, the first forming station upper tooling assembly 510and the first forming station lower tooling assembly 520 are structuredto form a shell body 22 including a center panel 30, a countersink 32, achuck wall 34, a can fit radius 35, a crown radius 36, and a curl 38,disposing 1006 the blank between the first forming station upper toolingassembly 510 and the first forming station lower tooling assembly 520,clamping 1008 any of the can fit radius portion 15, the crown radiusportion 16, and the curl portion 18 between the first forming stationupper tooling assembly 510 and the first forming station lower toolingassembly 520, and performing 1010 forming operations. Performing 1010forming operations includes draw-stretching 1020 any, or all, of thechuck wall portion 14, can fit radius portion 15, the crown radiusportion 16, the curl portion 18, and/or the outer portion 26 to form anyof a draw-stretched chuck wall 34, draw-stretched can fit radius 35, adraw-stretched crown radius 36, and/or a draw-stretched curl 38 (or adraw-stretch outer portion 26), and forming 1022 the countersink portion12 into a counter sink 32. As described above, following the formation1022 of the counter sink 32, the center panel 30 has a thicknesscorresponding to the blank 10 which, in turn, has a thicknesscorresponding to the sheet material 1.

Further providing 1004 a press assembly 500 includes providing 1030 afirst forming station upper tooling assembly 510 that includes a blank &draw die punch 512, an upper piston 514, and a die center punch 516,providing 1032 a first forming station lower tooling assembly 520 thatincludes a lower piston 522, a die core ring 524, and a panel punch 526,wherein the first forming station upper blank & draw die punch 512includes an inner radial surface 536, wherein the first forming stationupper blank & draw die punch inner radial surface 536 is a reducedradius, wherein the first forming station lower die core ring 524includes an outer radius 546, wherein the first forming station lowerdie core ring outer radius 546 is a diminished radius. Further,providing 1004 a press assembly 500 includes providing 1034 the firstforming station upper blank & draw die punch 512 wherein the innerradial surface 536 is about a 0.019 inch radius, and, providing 1036 thefirst forming station lower die core ring 524 wherein outer radius 546is about a 0.022 inch radius.

Further, draw-stretching 1020 the chuck wall portion 14, can fit radiusportion 15, the crown radius portion 16, and/or the curl portion 18 toform a draw-stretched can fit radius 35, a draw-stretched crown radius36, and/or a draw-stretched curl 38 (or a draw-stretch outer portion 26)includes applying 1040 a force of between about 1,153 lbf and about3,890 lbf to the blank 10, and/or, applying 1042 a force of about 2,442lbf to the blank 10.

In an exemplary embodiment, cutting 1002 a blank 10 from the sheetmaterial 1 includes cutting 1050 a blank 10 with a reduced volume. Asnoted above, cutting a blank 10 is equivalent to providing a blank;thus, as used herein, cutting 1050 a blank with a reduced volume is thesame as providing a blank 10 with a reduced volume. Further, in anexemplary embodiment, performing 1010 forming operations includesforming 1060 the blank 10 into a standard beverage shell 20′.

As noted above, the example used is generally an aluminum standardbeverage shell 20′. It is understood, however, that the conceptdisclosed above is also applicable to can ends made of other materialssuch as, but not limited to, steel and steel alloys. It is furtherunderstood that steel cans and can ends are typically made from materialwith a base thickness thinner than aluminum can ends. Thus, a steel canend that includes the down-gauging concept disclosed herein would have athinner base thickness than the dimensions for an aluminum can, asdescribed below, and a thinner base thickness than the metal used tomake the can ends that do not include the concept disclosed herein.

While specific embodiments of the invention have been described indetail, it will be appreciated by those skilled in the art that variousmodifications and alternatives to those details could be developed inlight of the overall teachings of the disclosure. Accordingly, theparticular arrangements disclosed are meant to be illustrative only andnot limiting as to the scope of invention which is to be given the fullbreadth of the claims appended and any and all equivalents thereof.

What is claimed is:
 1. A shell comprising: a body including a centerpanel, a countersink, a chuck wall, a can fit radius, a crown radius,and a curl; wherein said center panel and said countersink have a basethickness; and wherein said body has a reduced volume.
 2. The shell ofclaim 1 wherein said crown radius is a draw-stretched crown radius. 3.The shell of claim 2 wherein said shell body has one of a reducedprofile or a maximum reduced profile
 4. The shell of claim 1 wherein:said body is aluminum; said countersink has a general thickness ofbetween about 0.0104 inch and about 0.0078 inch; said center panel has ageneral thickness of between about 0.0104 inch and about 0.0078 inch;and said draw-stretched crown radius has a general thickness of betweenabout 0.009 inch and about 0.0064 inch.
 5. The shell of claim 4 wherein:said countersink has a general thickness of about 0.0086 inch; saidcenter panel has a general thickness of about 0.0086 inch; and saidcrown radius has a general thickness of about 0.0076 inch.
 6. The shellof claim 1 wherein: said body is steel; said countersink has a generalthickness of between about 0.0065 inch and about 0.0090 inch; saidcenter panel has a general thickness of between about 0.0065 inch andabout 0.0090 inch; and said crown radius has a general thickness ofbetween about 0.0050 inch and about 0.0090 inch.
 7. The shell of claim 6wherein: said countersink has a general thickness of about 0.0080 inch;said center panel has a general thickness of about 0.0080 inch; and saidcrown radius has a general thickness of about 0.0080 inch.
 8. A pressassembly structured to form a shell from a blank cut from sheetmaterial, said sheet material having a base thickness, said presscomprising: a frame; a number of press stations including a firstforming station; said first forming station including an upper toolingassembly and a lower tooling assembly; said first forming station uppertooling assembly structured to move between an upper, first position,wherein said first forming station upper tooling assembly is spaced fromsaid first forming station lower tooling assembly, and a lower, secondposition, wherein said first forming station upper tooling assembly isimmediately adjacent said first forming station lower tooling assembly;wherein when said first forming station upper tooling assembly and saidfirst forming station lower tooling assembly are structured to form ashell body including a center panel, a countersink, a chuck wall, and acrown radius; wherein said first forming station upper tooling assemblyand said first forming station lower tooling assembly are furtherstructured to draw-stretch said crown radius to create a crown radiuswith a reduced thickness; and wherein said first forming station uppertooling assembly and said first foil ling station lower tooling assemblyare further structured to form said center panel and said countersink atsaid base thickness.
 9. The press assembly of claim 8 wherein: saidfirst forming station upper tooling assembly includes a blank & draw diepunch, an upper piston, and a die center punch; said first formingstation lower tooling assembly includes an lower piston, a die corering, and a panel punch; said first forming station upper blank & drawdie punch including an inner radius; wherein said first forming stationupper blank & draw die punch inner radius is a reduced radius; saidfirst forming station lower die core ring including an outer radius; andwherein said first forming station lower die core ring outer radius is adiminished radius.
 10. The press assembly of claim 9 wherein: said firstforming station upper blank & draw die punch inner radius is about a0.019 inch radius; and said first forming station lower die core ringouter radius is about a 0.022 inch radius.
 11. The press assembly ofclaim 9 wherein, when said upper tooling assembly is in said secondposition, said first forming station upper blank & draw die punch andsaid first forming station lower piston clamp said blank.
 12. The pressassembly of claim 11 wherein, when said upper tooling assembly is insaid second position, said first forming station upper piston and saidfirst forming station lower die core ring apply a force of between about100 psi and about 600 psi to said blank.
 13. The press assembly of claim12 wherein, when said upper tooling assembly is in said second position,said first forming station upper piston and said first forming stationlower die core ring apply a force of about 110 psi to said blank.
 14. Amethod of forming a shell comprising: providing a sheet material, saidsheet material having a base thickness; cutting a blank from said sheetmaterial, said blank including a countersink portion, a chuck wallportion, and a crown radius portion; providing a press assemblyincluding a frame, a number of press stations including a first formingstation, said first forming station including an upper tooling assemblyand a lower tooling assembly, said first forming station upper toolingassembly structured to move between an upper, first position, whereinsaid first forming station upper tooling assembly is spaced from saidfirst forming station lower tooling assembly, and a lower, secondposition, wherein said first forming station upper tooling assembly isimmediately adjacent said first forming station lower tooling assembly,wherein when said first forming station upper tooling assembly and saidfirst forming station lower tooling assembly are in said secondposition, said first forming station upper tooling assembly and saidfirst forming station lower tooling assembly are structured to form ashell body including a center panel, a countersink, and a crown radius;disposing said blank between said upper tooling assembly and said lowertooling assembly; clamping said crown radius portion between said firstforming station upper tooling assembly and said first forming stationlower tooling assembly; performing forming operations including:draw-stretching said crown radius portion to form a draw-stretched crownradius; forming said countersink portion into a counter sink; anddraw-stretching said chuck wall portion into a draw-stretched chuckwall.
 15. The method of claim 14 wherein said counter sink has athickness corresponding to said sheet material base thickness.
 16. Themethod of claim 13 wherein providing a press assembly includes:providing a first forming station upper tooling assembly that includes ablank & draw die punch, an upper piston, and a die center punch;providing a first forming station lower tooling assembly that includes alower piston, a die core ring, and a panel punch; wherein said firstforming station upper blank & draw die punch includes an inner radius;wherein said first forming station upper blank & draw die punch innerradius is a reduced radius; wherein said first forming station lower diecore ring includes an outer radius; and wherein said first formingstation lower die core ring outer radius is a diminished radius.
 17. Themethod of claim 16 wherein providing a press assembly includes:providing said first forming station upper blank & draw die punchwherein said inner radius is about a 0.019 inch radius; and providingsaid first forming station lower die core ring wherein outer radius isabout a 0.022 inch radius.
 18. The method of claim 14 whereindraw-stretching said crown radius portion to form a draw-stretched crownradius include applying a force of between about 100 psi and about 600psi to said blank.
 19. The method of claim 18 wherein draw-stretchingsaid crown radius portion to form a draw-stretched crown radius includeapplying a force of about 110 psi.
 20. The method of claim 14 whereincutting a blank from said sheet material includes cutting a blank with areduced volume.
 21. The method of claim 20 wherein performing formingoperations includes forming said blank into a standard beverage shell.